Konecranes' waste technologies unlock bioenergy potential

24 July 2016

Editorial

A broad range
of lifting and materials handling technologies specifically designed for waste-to-energy
(WTE) and biomass applications is being introduced to Australasia by Konecranes
as the region develops its bioenergy potential.

The
technologies – including unmanned full automation, remote operation stations,
remote monitoring and maintenance reporting products – are focused on
applications such as biomass, refuse and ash/slag.

Konecranes
Australia National Industrial Equipment Manager, Mr Peter Monaghan says the WTE
market has considerable growth potential because these technologies allow
customers to save money and run their businesses in a more sustainable manner.

“Our WTE
cranes can be equipped with Global Technical Support connection, remote
monitoring and a computer interface capable of semi or fully unmanned
automation or a remote for manual handling, as well as a range of features and
benefits to maximise production and minimize running costs,” said Mr Monaghan.

Konecranes
waste handling cranes are designed with smart features, which manage critical
crane functions to reduce structural stress, increase efficiency and prolong
equipment life. For example, sway control minimises load sway from bridge and
trolley motions, reducing collisions between the bucket and the pit walls or
hopper, and preventing equipment damage. It increases operator confidence,
reduces training time and allows the crane to operate to its full potential.

“As an
industry leader in cranes and crane maintenance, with over 50 years experience
in the waste and biomass handling applications, Konecranes is able to provide
complete crane systems for the renewable energy industry,” says Mr Monaghan. “Cranes
play a crucial role in waste-to-energy as well as other modern incineration
plants where tight environmental management guidelines are applied. A
continuous material handling system with maximum safety and efficiency and
minimum downtime is vital.”

Remote Operation

Konecranes can
replace entirely the crane operator pulpit chair and pulpit itself with a
remote operators station or ROS which allows someone to operate the crane via
cameras from a central operations room located in the facility. This ROS ensures all personnel are removed
from harm’s way.

Konecranes Waste-to-Energy crane technology

Konecranes Biomass Handling Crane technologies recognise that many biomass energy
plants today use cranes instead of front-end loaders or conveyors. Cranes need
less energy, can operate unmanned in full automation, eliminate diesel fumes
from inside your plant, and maximize your available floor space, just to name a
few advantages.

Konecranes
biomass handling cranes automatically start the working cycle to transfer the
material from the reception pocket to the adjacent storage. Likewise, the crane
automatically starts the working cycle to fill the hopper from the storage
after the reception of the command “fill the hopper” from the sensor of the
hopper.

The storage is
managed by the crane. Every time crane deposits or picks up material, it
updates the storage in that coordinate location. The same modular solutions
used in Konecranes WTE cranes are applicable to Biomass Handling Cranes.

Konecranes refuse handling cranes are designed to meet the demanding loads of waste
management plants, where minimal downtime is crucial. Important components like
hoisting trolleys, drives and grapples have been engineered to reduce
maintenance requirements.

Each crane
features Konecranes’ advanced integrated rope/cable drum. The vertical power
cable for the bucket is wound onto the rope drum and is driven by the hoisting
machinery. With this unique solution, savings in maintenance costs are
substantial.

Konecranes refuse plant cranes recognise the importance of a continuous material handling system, from
the reception of the waste to mixing and feeding. If a waste handling crane
stops, the whole process is in danger. Konecranes proprietary smart features manage
critical crane functions to reduce structural stress, increase efficiency and
prolong equipment life.

Sway Control
minimizes load sway from bridge and trolley motions, reducing collisions
between the grab and the pit walls or hopper, as well as preventing equipment
damage. Sway Control increases operator confidence, reduces training time and
allows the crane to operate to its full potential.

Konecranes ash (or slag) handling cranes are ruggedly designed for harsh
environments. These cranes are used to distribute slag under the conveyor line
to the other areas in the slag bunker 24 hours a day as well as loading trucks
during the daytime. Sometimes the ferrous rejects have not been separated from
the slag, causing higher requirements for the buckets.

To achieve
better penetration into the slag, the edges of claws can be provided with
special teeth.

The Konecranes Main User Interface,or MUI, is Konecranes’ new
standard solution for programming waste-to-energy automation. Accessed from the
MUI station, the MUI features a computer and 23-inch LED panel screen, keyboard
and mouse. This computer is fully integrated with the crane’s PLC system, while
isolated from outside networks. It allows the operator to schedule and program
a week-long agenda that includes up to 20 different work routines in full
automation, giving plant managers enhanced flexibility to manage pit operations
for receiving, mixing and burning waste.

In seasons
where flexibility is not as important, facilities can repeat the Monday through
Sunday agenda indefinitely without accessing the crane–except to take it out of
automation for scheduled inspections and maintenance. In addition, the MUI
monitors crane operations, including usage statistics, error messages and
equipment condition. The system also generates summary reports to help managers
optimize maintenance and alert them if more operator training is needed.

Newsletter sign-up

Ferret.com.au is Australia’s leading hub for the manufacturing, industrial and mining industries. Owned and operated by Prime Creative Media, Ferret.com.au provides a comprehensive central online source containing the latest product, supplier and industry news updates attracting more than 70,000 unique visitors each month.
Ferret.com.au is the official partner of Australian Mining and Manufacturers' Monthly.